Abstract: Composite layers for controlling dendrite growth in electrochemical cells having active-metal anodes prone to dendrite growth during cycling. In some embodiments, one of the composite layers includes a porous matrix having pores, solid electrolyte particles, and one or more alloying materials that alloy with the active metal so that each dendrite that contacts the alloying material alloys with it to prevent that dendrite from growing beyond the composite layer. In some embodiments, another of the composite layers includes a gel electrolyte and solid electrolyte particles dispersed in the gel electrolyte. Each of these two types of composite layers can be deployed in an electrochemical cell separately from one another or together with one another, with the gel-electrolyte composite layer typically being deployed in contact with an active-metal anode and the porous composite layer typically being deployed between an active-metal anode and a separator.

Abstract: Battery core packs employing minimum cell-face pressure containment devices and methods are disclosed for minimizing dendrite growth and increasing cycle life of metal and metal-ion battery cells.

Abstract: Functionalized porous matrices that store functional liquids prior to being installed into an electrochemical cell, such as a battery cell or supercapacitor. In some embodiments, a functionalized porous matrix of the present disclosure may be deployed as a separator in the cell. In some embodiments, the porous matrix provides a storage reservoir for one or more functional liquids that participate(s) in a process within a cell, such as a process that inhibits or prevents growth and/or proliferation of filaments (e.g., dendrites) of an active electrode material. For example, in some embodiments, a functional liquid may be reactive to the active material so that when a filament encounters the functional liquid a reaction between the filament and the functional liquid forms a stable product that inhibits further growth of the filament. In some embodiments, the functional liquid participates in forming a solid electrolyte interphase layer.

Abstract: Alkali metal secondary batteries that include anodes constructed from alkali metal foil applied to only one side of a porous current collector metal foil. Openings in the porous current collectors permit alkali metal accessibility on both sides of the anode structure. Such anode constructions enable the utilization of lower-cost and more commonly available alkali metal foil thickness, while still achieving high cell cycle life at a significantly reduced cost. Aspects of the present disclosure also include batteries with porous current collectors having increased volumetric and gravimetric energy densities, and methods of manufacturing anodes with porous current collectors.

Abstract: A method of making a positive electrode includes forming a slurry of particles using an electrode formulation, a diluent, and oxalic acid, coating the slurry on a collector and drying the coating on the collector to form the positive electrode. The electrode formulation includes an electrode active material, a conductive carbon source, an organic polymeric binder, and a water soluble polymer. The diluent consists essentially of water.

Abstract: A method of forming anodes for electrochemical devices by laminating a metal foil to a current collector and creating anode-active-material patches, composed of the metal foil, that are spaced from one another by inter-patch regions, wherein each inter-patch region provides a location for forming one or more electrical tabs of the finished anodes. The method can further include applying conductive-coating patches to the current collector prior to laminating the metal foil to the current collector, wherein each conductive-coating patch corresponds to one of the anode-active-material patches. In some embodiments, the conductive-coating patches can assist with forming the anode-active-material patches and/or can improve the cycling performance of an electrochemical device made using anodes made therewith. Anodes containing anode-active material and conductive coatings applied to current collectors are also disclosed.

Abstract: Alkali metal secondary batteries that include anodes constructed from alkali metal foil applied to only one side of a porous current collector metal foil. Openings in the porous current collectors permit alkali metal accessibility on both sides of the anode structure. Such anode constructions enable the utilization of lower-cost and more commonly available alkali metal foil thickness, while still achieving high cell cycle life at a significantly reduced cost. Aspects of the present disclosure also include batteries with porous current collectors having increased volumetric and gravimetric energy densities, and methods of manufacturing anodes with porous current collectors.

Abstract: Alkali metal secondary batteries that include anodes constructed from alkali metal foil applied to only one side of a porous current collector metal foil. Openings in the porous current collectors permit alkali metal accessibility on both sides of the anode structure. Such anode constructions enable the utilization of lower-cost and more commonly available alkali metal foil thickness, while still achieving high cell cycle life at a significantly reduced cost. Aspects of the present disclosure also include batteries with porous current collectors having increased volumetric and gravimetric energy densities, and methods of manufacturing anodes with porous current collectors.

Abstract: A method of forming anodes for electrochemical devices by laminating a metal foil to a current collector and creating anode-active-material patches, composed of the metal foil, that are spaced from one another by inter-patch regions, wherein each inter-patch region provides a location for forming one or more electrical tabs of the finished anodes. The method can further include applying conductive-coating patches to the current collector prior to laminating the metal foil to the current collector, wherein each conductive-coating patch corresponds to one of the anode-active-material patches. In some embodiments, the conductive-coating patches can assist with forming the anode-active-material patches and/or can improve the cycling performance of an electrochemical device made using anodes made therewith. Anodes containing anode-active material and conductive coatings applied to current collectors are also disclosed.

Abstract: Battery core packs employing minimum cell-face pressure containment devices and methods are disclosed for minimizing dendrite growth and increasing cycle life of metal and metal-ion battery cells.

Abstract: Battery core packs employing minimum cell-face pressure containment devices and methods are disclosed for minimizing dendrite growth and increasing cycle life of metal and metal-ion battery cells.

Abstract: Alkali metal secondary batteries that include anodes constructed from alkali metal foil applied to only one side of a porous current collector metal foil. Openings in the porous current collectors permit alkali metal accessibility on both sides of the anode structure. Such anode constructions enable the utilization of lower-cost and more commonly available alkali metal foil thickness, while still achieving high cell cycle life at a significantly reduced cost. Aspects of the present disclosure also include batteries with porous current collectors having increased volumetric and gravimetric energy densities, and methods of manufacturing anodes with porous current collectors.

Abstract: Anode subassembly sheets that include a lithium-metal layer sandwiched between a pair of separator layers to ease handling of the lithium metal to promote fast and efficient stacked-jellyroll assembly. In some embodiments, the separator layers are pressure laminated to the lithium-metal layer without any bonding agent. In some embodiments, a stacked jellyroll is made by alternatingly stacking anode subassembly sheets with cathode sheets. In some embodiments, a functional coating beneficial to the lithium-metal layer is provided to one or more separator layers prior to laminating the separator(s) to the lithium metal layer. Lithium-metal batteries made using stacked jellyrolls made in accordance with aspects of the disclosure are also described.

Abstract: In one embodiment, a positive electrode is formed by a process that includes forming a slurry including particles dispersed within a liquid from a electrode formulation and the liquid such that the particles have a particle size distribution D50 of 15 microns or less, coating the slurry on a collector; and drying the coated collector to form the positive electrode. The electrode formulation includes an electrode active material, a conductive carbon source, an organic polymeric binder, and a water-soluble polymer. The liquid consists essentially of water or a mixture of water and an alcohol. When the liquid consists essentially of the mixture, the alcohol is present in an amount of less than 10% by weight, based on the weight of the slurry. When the liquid consists essentially of water, the slurry is formed from the electrode formulation, the liquid, and an arene-capped polyoxoethylene surfactant.

Abstract: The present disclosure relates to micro-hybrid battery modules that include at least one battery cell having a titanate-based oxide anode active material with spinel structure and a high voltage spinel (LiMn2?xMxO4) cathode active material. The battery module may be configured to couple to an energy storage unit to enable the module to be used in start-stop applications.

Abstract: The present disclosure relates generally to the field of lithium ion batteries and battery modules. More specifically, the present disclosure relates to a battery module including a lithium ion battery cell having a cathode with a cathode active layer and an anode with an anode active layer. The anode active layer includes at least one polyvinylidene fluoride (PVDF) binder, a conductive carbon, and a secondary lithium titanate oxide (LTO), wherein the secondary LTO includes secondary LTO particles having an average particle size (D50) greater than 2 micrometers (?m).

Abstract: The present disclosure relates generally to the field of lithium ion batteries and battery modules. More specifically, the present disclosure relates to lithium ion batteries that use lithium titanate oxide (LTO) as the anode active material. A battery module includes a lithium ion battery cell including an anode having an active layer. The active layer includes a secondary lithium titanate oxide (LTO) having an average particle size (D50) greater than 2 micrometers (?m).

Abstract: The present disclosure relates to micro-hybrid battery modules that include at least one battery cell having a titanate-based oxide anode active material with spinel structure and a high voltage spinel (LiMn2-xMxO4) cathode active material. The battery module may be configured to couple to an energy storage unit to enable the module to be used in start-stop applications.

Abstract: A method of making a positive electrode includes forming a slurry of particles using an electrode formulation, a diluent, and oxalic acid, coating the slurry on a collector and drying the coating on the collector to form the positive electrode. The electrode formulation includes an electrode active material, a conductive carbon source, an organic polymeric binder, and a water soluble polymer. The diluent consists essentially of water.

Abstract: In one embodiment, a positive electrode is formed by a process that includes forming a slurry including particles dispersed within a liquid from a electrode formulation and the liquid such that the particles have a particle size distribution D50 of 15 microns or less, coating the slurry on a collector; and drying the coated collector to form the positive electrode. The electrode formulation includes an electrode active material, a conductive carbon source, an organic polymeric binder, and a water-soluble polymer. The liquid consists essentially of water or a mixture of water and an alcohol. When the liquid consists essentially of the mixture, the alcohol is present in an amount of less than 10% by weight, based on the weight of the slurry. When the liquid consists essentially of water, the slurry is formed from the electrode formulation, the liquid, and an arene-capped polyoxoethylene surfactant.